U.S. patent number 4,798,756 [Application Number 07/140,771] was granted by the patent office on 1989-01-17 for laminate structure of interior finishing material.
This patent grant is currently assigned to Toyo Tire & Rubber Company Limited. Invention is credited to Shigeyoshi Fukushima, Shigetoshi Mimura, Hidehiro Uno.
United States Patent |
4,798,756 |
Fukushima , et al. |
January 17, 1989 |
Laminate structure of interior finishing material
Abstract
The present invention provides laminate structures of interior
finishing material having suitable air permeability and sound
absorbing properties.
Inventors: |
Fukushima; Shigeyoshi (Nagoya,
JP), Uno; Hidehiro (Nagoya, JP), Mimura;
Shigetoshi (Toyota, JP) |
Assignee: |
Toyo Tire & Rubber Company
Limited (Osaka, JP)
|
Family
ID: |
26335550 |
Appl.
No.: |
07/140,771 |
Filed: |
January 4, 1988 |
Foreign Application Priority Data
|
|
|
|
|
Jan 9, 1987 [JP] |
|
|
62-2210[U] |
Jan 9, 1987 [JP] |
|
|
62-2211[U] |
|
Current U.S.
Class: |
428/198;
428/317.1; 442/225; 428/317.7 |
Current CPC
Class: |
B32B
27/12 (20130101); B60R 13/0815 (20130101); B32B
7/14 (20130101); B32B 5/022 (20130101); B32B
5/18 (20130101); B32B 5/26 (20130101); B32B
5/245 (20130101); B60R 13/02 (20130101); B32B
2307/724 (20130101); Y10T 428/249982 (20150401); Y10T
442/3358 (20150401); B32B 2605/006 (20130101); B32B
2315/085 (20130101); B32B 2305/20 (20130101); B32B
2605/003 (20130101); B32B 2262/101 (20130101); Y10T
428/249985 (20150401); Y10T 428/24826 (20150115); B32B
2307/102 (20130101); B32B 2266/0278 (20130101) |
Current International
Class: |
B32B
27/12 (20060101); B60R 13/08 (20060101); B60R
13/02 (20060101); B32B 007/04 (); B32B 003/26 ();
B32B 017/00 () |
Field of
Search: |
;428/198,246,247,251,252,317.1,317.7 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Van Balen; William J.
Attorney, Agent or Firm: Larson and Taylor
Claims
We claim:
1. A laminate structure of interior finishing material having
suitable air permeability and sound absorbing properties, the
laminate structure comprising a thermoplastic rigid polyurethane
foam layer in the form of a platelike member, a reticular glass
cloth layer provided on at least one surface of the foam layer, a
nonwoven fabric layer provided on one surface of the assembly of
the foam and cloth layers, and a facing layer provided on the other
surface of the assembly, the fabric layer and the facing layer
being individually provided on the different surfaces of the
assembly and being adhered by heating to the assembly with a
hotmelt adhesive film having a plurality of slits therein.
2. A laminate structure of interior finishing material having
suitable air permeability and sound absorbing properties, the
laminate structure comprising a thermoplastic rigid polyurethane
foam layer in the form of a platelike member, a reinforcing layer
of glass paper provided on each surface of the foam layer and
adhered thereto with a hotmelt adhesive film having a plurality of
slits therein, and a facing layer provided on the reinforcing layer
over one surface of the foam layer.
Description
The present invention relates to interior finishing materials, and
more particularly to laminate structures of interior finishing
material for use in motor vehicles for shaped ceilings, door trims,
pillar garnishes, etc.
Conventional interior finishing materials for motor vehicles
include molded materials which are recently used for lining the
inside ceilings of motor vehicles. These materials include, for
example, that prepared by molding glass fiber into a solid sheet
with use of phenolic resin or like thermosetting resin. This
material has drawbacks. Glass monofilaments, when adhering to the
skin, cause discomfort, such as itching, to persons traveling in
the vehicle. Glass fiber is expensive and must therefore be used in
a limited amount, so that the glass fiber sheet needs to have the
smallest possible thickness, which results in diminished rigidity.
Another material is known which is prepared from a mixture of
natural fiber and synthetic fiber by admixing a suitable amount of
phenolic resin or like thermosetting resin with the mixture and
subjecting the resulting mixture to compression molding. The
material is excessively heavy for use as a ceiling material, while
the molding conditions required, i.e. increased pressure of 1 to 3
kg/cm.sup.2, mold temperature of 160.degree. to 200.degree. C. and
heating time of 1 to 4 minutes, involve disadvantages. Another
material is known which is prepared by sandwiching a metal lath net
between two sheets of crosslinked highly expanded polyethylene
foam. Although the lath net used has a considerably great
thickness, the material has low rigidity, is excessively heavy for
use as a ceiling material and can not be designed with great
freedom. The conventional molded materials further include one
comprising a layer of expanded thermoplastic synthetic resin foam,
such as expanded polystyrene foam, and a reinforcing layer of
natural fiber, synthetic fiber or the like. This material is not
satisfactory as a lightweight material since the resin foam layer
has a low expansion ratio of 3 to 15 times. The layer is made up of
closed cells and accordingly has a low sound absorbing property
(Examined Japanese Patent Publication No. 53257/1986).
The main object of the invention is to provide an interior
finishing material free of the foregoing drawbacks.
The above and other objects of the invention will become apparent
from the following description.
The present invention provides as an embodiment thereof a laminate
structure of interior finishing material having suitable air
permeability and sound absorbing properties, the laminate structure
comprising a thermoplastic rigid polyurethane foam layer in the
form of a plate-like member or slice, a reticular glass cloth layer
provided on at least one surface of the foam layer, a nonwoven
fabric layer provided on one surface of the assembly of the foam
and cloth layers, and a facing layer provided on the other surface
of the assembly, the fabric layer and the facing layer being
individually provided on the different surfaces of the assembly
individually and being adhered to the assembly with a slitted
hotmelt adhesive film having a plurality of slits therein.
As another embodiment, the invention further provides a laminate
structure of interior finishing material having suitable air
permeability and sound absorbing properties, the laminate structure
comprising a thermoplastic rigid polyurethane foam layer in the
form of a platelike member or slice, a reinforcing layer of glass
paper provided on each surface of the foam layer and adhered
thereto with a hotmelt adhesive film having a plurality of slits
therein, and a facing layer provided on the reinforcing layer over
one surface of the foam layer.
DESCRIPTION OF DRAWINGS
FIGS. 1 to 3 are sectional views showing laminate structures of
interior finishing material of the invention:
FIG. 4 shows a reticular glass cloth;
FIG. 5 shows a slitted hotmelt adhesive film;
FIG. 6 is an enlarged view showing the surface of the film;
FIG. 7 is a view schematically showing the film with its slits
enlarged to mesh-like openings by heating; and
FIG. 8 is a sectional view showing another laminate structure of
interior finishing material of the invention.
The first embodiment of the invention will be described with
reference to FIGS. 1 to 3. The embodiment comprises a thermoplastic
rigid polyurethane foam layer 1, at least one reticular glass cloth
layer 2, a nonwoven fabric layer 3 and hotmelt adhesive film layers
4 formed with minute slits therein. Indicated at 5 is a facing
layer.
The polyurethane foam layer 1 to be used for the interior finishing
laminate material of the invention is prepared by slicing a
thermoplastic rigid polyurethane foam which is well known. Examples
of the thermoplastic rigid polyurethane foam are described in UK
Patent GB No. 2028714 B, Modern Plastics International, 6 (3) 17,
1976, etc.
The reticular glass cloth layer 2 and the nonwoven fabric layer 3
each serve as a reinforcing layer. FIG. 4 shows a reticular glass
cloth useful as the former layer. A synthetic fiber nonwoven fabric
is used as the latter layer. Examples of useful synthetic fibers
are polyamide, polyvinyl alcohol, polyvinylidene chloride,
polyvinyl chloride, polyester, polyacrylonitrile, polyethylene,
polypropylene, polyurethane and like fibers. Glass fiber is also
useful. With respect to rigidity, a glass fiber nonwoven fabric is
most desirable for use as the nonwoven layer shown in FIG. 2. A
hotmelt adhesive is used in the form of a film as the layer 4. The
hotmelt adhesive film to be used in this invention is formed with
minute slits as seen in FIG. 5. FIG. 6 is an enlarged view showing
the surface of the film. When the film is heated, the slits are
enlarged to render the film recticular as shown in FIG. 7,
consequently obviating the likelihood that the film will impair the
air permeability and sound absorbing properties of the present
material.
For example, a nonwoven fabric (print), or a knitted or woven
fabric of fiber is used as the facing layer 5. Also useful is a
laminate of such a fabric and a synthetic resin foam, typical of
which is soft polyurethane foam. To assure the interior finishing
material of the desirable air permeability and sound absorbing
properties, the synthetic resin foam must substantially be open
cellular.
The interior finishing laminate material of FIG. 1 to 3 is
prepared, for example, in the following manner. The layers, other
than the facing layer, are bonded together in the form of a
laminate using a heat press, heat rolls, etc. The laminate is
heated preferably at 180.degree. to 190.degree. C. for 15 to 35
seconds to obtain a base material. The facing layer was placed over
the hotmelt adhesive film layer opposite to the other film layer
adhering the nonwoven fabric layer, and the resulting assembly was
pressed after heating. The heating is conducted preferably with use
of an infrared heater, at 350.degree. to 400.degree. C. for 25 to
35 seconds. In the heating process, the surface temperature of the
assembly is brought about at 180.degree. to 190.degree. C. The
assembly is taken out from the infrared heater and then placed in a
press-molding for heating at a temperature below 130.degree. C. for
several tens of seconds, preferably at 60.degree. to 65.degree. C.
for 30 to 60 seconds. After the press-molding, the resulting
pressed panel is taken out from the molding. The adhesive film
layer beneath the facing layer may be formed with release paper
superposed thereon.
With reference to FIG. 8, the second embodiment of the invention
comprises a thermoplastic rigid polyurethane foam layer 1, glass
paper layers 2', hotmelt adhesive film layers 4 formed with minute
slits, and a facing layer 5 provided over one of the glass paper
layers.
The polyurethane foam layer 1, the adhesive layer 4 and the facing
layer 5 to be used can be the same as those used for the first
embodiment. As the glass paper layer 2'serving as a reinforcing
layer, paper is used which is prepared by forming a web of glass
fiber by a paper making machine and applying a synthetic resin to
the web to fix the fiber and form a hard sheet. When a small amount
of pulp is admixed with the glass fiber, the web can be formed
easily at a lower cost. Examples of useful synthetic resins to be
applied to the web are melamine resin, urea resin, epoxy resin,
polyvinyl chloride (PVC), polyvinyl alcohol (PVA), polyvinyl
acetate (PVA.sub.c), polyvinyl butyral, acrylic acid ester
copolymer, butadiene copolymer and the like.
The interior finishing laminate material of FIG. 8 according to the
invention is prepared, for example, by bonding together the layers,
other than the facing layer, in the form of a laminate, by heating
to obtain a base material, placing the facing layer having the
adhesive over one of the glass paper layers, and pressing the
assembly after heating. The conditions of heating and pressing in
the preparation of the base material and the assembly are the same
as those described in the laminate material of FIG. 1 to 3.
The material of the invention is made lightweight by the use of a
polyurethane foam having a high expansion ratio. The polyurethane
is a special rigid polyurethane having thermoplastic properties and
improved shaping capabilities and permitting designing with greater
freedom. The use of the reticular glass cloth and the nonwoven
fabric, or the glass paper for reinforcement eliminates the
likelihood of glass monofilaments adhering to the skin to preclude
discomfort. The forming conditions include heating with upper and
lower infrared heaters, at about 350.degree. to 400.degree. C. for
25 to 35 seconds and pressing for several tens seconds, for
example, 30 seconds. The material can therefore be formed within a
short period of time. Further the material can be prepared at a low
temperature of about 180.degree. to 190.degree. C. at the surface
of the laminate. The hotmelt adhesive film having minute slits and
used for adhering the reinforcing layer or the like to the
polyurethane layer does not impair the air permeability and sound
absorbing properties of the present material.
The present invention will be described in detail with reference to
the following examples.
EXAMPLE 1
A thermoplastic rigid polyurethane foam (0.045 g/cm.sup.3 in
density and 1.8 mm in cell size) was sliced to obtain a plate 8 mm
in thickness, 1300 mm in width and 1700 mm in length. A base plate
was prepared by sandwiching the foam plate between two sheets of
recticular glass cloth (weighing 43 g/m.sup.2) and further between
two sheets of hotmelt adhesive film (weighing 50 g/m.sup.2), having
a multiplicity of slits therein placing a polyester nonwoven fabric
(weighing 50 g/m.sup.2) over one surface of the resulting assembly,
placing release paper over the other surface of the assembly,
bonding the layers together by a heat press at about 180.degree. C.
and removing the release paper.
A facing material prepared by laminating a sheet of soft
polyurethane foam, 2 mm in thickness, to nylon tricot was placed
over the film exposed surface of the base plate. A motor vehicle
ceiling member was prepared by heating the resulting assembly by
two far infrared heaters, spaced apart by about 300 mm, from above
and below at about 400.degree. C. for about 25 seconds to bring
about a surface temperature of about 180.degree. C., and treating
the assembly by a press at a die temperature of about 65.degree. C.
for 30 seconds. The ceiling member had the section of FIG. 1 in
section, a thickness of about 7 mm and a high quality.
EXAMPLE 2
A thermoplastic rigid polyurethane foam was sliced in the same
manner as in Example 1 into a plate, 8 mm in thickness, 1300 mm in
width and 1700 mm in length. A base plate was prepared by placing
in layers a glass fiber nonwoven fabric (weighing 50 g/m.sup.2), a
slitted hotmelt adhesive film (weighing 50 g/m.sup.w), the
polyurethane foam plate, a reticular glass cloth (weighing 43
g/m.sup.2), a hotmelt adhesive film (weighing 50 g/m.sup.2) having
multiple slits therein and release paper, bonding the layers
together by a heat press at about 180.degree. C. and removing the
release paper. A motor vehicle ceiling member was prepared by
placing nylon tricot serving as a facing material over the film
exposed surface of the base plate, heating the assembly under the
same conditions as in Example 1 and press-forming the assembly. The
ceiling member had the section of FIG. 2, a thickness of about 5 mm
and a high quality.
EXAMPLE 3
A thermoplastic rigid polyurethane foam (0.045 g/cm.sup.3 in
density and 1.8 mm in cell size) was sliced to obtain a plate, 8 mm
in thickness, 1300 mm in width and 1700 mm in length. Glass paper
weighing 50 g/m.sup.2 and coated with a binder of epoxy resin was
bonded to the opposite surfaces of the plate with a slitted hotmelt
adhesive film having a plurality of slits therein and weighing 50
g/m.sup.2 by heat-pressing at about 180.degree. C. to obtain a base
plate. Nylon tricot serving as a facing material and having
laminated thereof a 2--mm--thick soft polyurethane foam sheet lined
with a hotmelt adhesive layer was placed over one surface of the
base plate. The assembly was then heated by far infrared heaters,
spaced apart by about 300 mm, from above and below at about
400.degree. C. for about 25 seconds to bring about a surface
temperature of about 180.degree. C. and treated by a press at a die
temperature of about 65.degree. C. for 30 seconds, whereby a motor
vehicle ceiling member was obtained which had the section of FIG.
8, a thickness of about 7 mm and a high quality.
* * * * *